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For me the top extensions are too short. Looks to be only 3-4" max. I actually put lumber on my racks and that's only 2-3 2x's stacked. Nit picking I know.

Looks very nice BTW. Does it fit in an acceptable size box for UPS or FedEx shipping? I forget the max sizes they accept. You may be able to make the design a breakdown design if the horizontal bar could slide down over the vertical supports and get secured with a bolt. Just a thought for decreasing shipping costs and box costs. I would also think about powercoating the frame as suggested above.

The height of the top is a bit of a compromise between looks and functionality. It still works good in my opinion but for just a work truck for a contractor, a little taller would probably be better.
As far as shipping goes, it just fall under the 130" max (length+girth) for UPS. I wouldn't buy it If I lived across the country though; the shipping is not cheap. A short hop across states might be worth it if this is just what the customer is looking for.

The rack itself may be too short. I crazily carry 20' pieces a lot on top of my rack and at this height the metal would probably whack the roof if I went over a bump. Even though it doesn't look as good, the top of my racks are ~ 7-8" above the roof.

Also it might be nice to have a full cleat in the middle and some other tie down point at the base.

"The rack mounts to the front stake pockets in the bed by a simple plate with a nut welded on the backside that sandwiches the edges of the stake pockets between it and the rack. It is surprisingly strong and means no drilling."

I looked at the pics and missed this part.

So, I said the bolt was too close to the pocket and would pull out if someone hit the brakes with the rack loaded heavily. If you sold one, some redneck would load 'er up. I also said "I'm just a hobby guy and don't like to judge the work of others, but you asked."

The rack itself may be too short. I crazily carry 20' pieces a lot on top of my rack and at this height the metal would probably whack the roof if I went over a bump. Even though it doesn't look as good, the top of my racks are ~ 7-8" above the roof.

Also it might be nice to have a full cleat in the middle and some other tie down point at the base.

Have you noticed any whistling?

My rack (I didn't make it):

with 20' sticks of steel there would definitely be a problem with this rack. I only built the front part that protects the cab, not the full rack like you have so tying things down is a bit different.
More tie down points will definitely go in the revised design. Thanks for the advice.

"The rack mounts to the front stake pockets in the bed by a simple plate with a nut welded on the backside that sandwiches the edges of the stake pockets between it and the rack. It is surprisingly strong and means no drilling."

I looked at the pics and missed this part.

So, I said the bolt was too close to the pocket and would pull out if someone hit the brakes with the rack loaded heavily. If you sold one, some redneck would load 'er up. I also said "I'm just a hobby guy and don't like to judge the work of others, but you asked."

So my critique was based on my inattention.

That was and still is a bit of a concern. I left enough room on the mounting brackets to drill a hole and mount through the bedrail at another point but this way was surprisingly strong.
I agree with you completely though that some idiot would overload this thing and expect me to fix it
Thanks for the advice Craig

with 20' sticks of steel there would definitely be a problem with this rack. I only built the front part that protects the cab, not the full rack like you have so tying things down is a bit different.
More tie down points will definitely go in the revised design. Thanks for the advice.

Oh and no whistling

Yeah, I wasn't sure if your rack was just one or two. Just one it makes more sense.

Oh and about the "buffer" I still need to pick up some rubber matting. Any good sources for something like that besides McMaster-Carr or the obvious Home Depot?

I looked for rubber material to bufer my rack that I am working on. After a bit of thinking on where I could get some medium sized pieces I remembered some PVC shower liner that I have left over from a job. Lowes and HD sell it by the foot as well as in sheets in the plumbing dept. If you know a tile guy, you might be able to grab some of his scraps cheap.